KT-Elektronik SOL3-5 Installation guide

Solar controller

SOL3-5

Installation and operating

manual

Firmware version 1.07

April 2011

Installation and operating manual KT-Elektronik

Warranty

We permanently enhance our products, therefore we reserve the right to make changes

to our products at any time and without prior notice.

We take no responsibility for the accuracy or completeness of this manual. No liability

can be accepted for the use of our products for a buyer specific purpose. Buyer claims,

especially claims for damages including lost profits or other financial losses are

excluded. This does not apply if the damage caused by intent or gross negligence. In

case of negligent violations of major contractual obligations, our liability is limited to the

foreseeable damage

Security advices

Only qualified personnel that is familiar with installation and

commissioning of this product is allowed to mount and put into

operation the device. Appropriate shipping and storage are assumed.

The product is designated for use in heavy current equipment.

Installation and maintenance have to be performed according to the

corresponding safety regulations.

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Table of contents

1 Operation ...................................................................................................................... 6

1.1 Controls .................................................................................................................. 6

1.1.1 Rotary pushbutton ........................................................................................... 6

1.1.2 Rotary switch ................................................................................................... 7

1.2 Operating modes for heating circuit ........................................................................ 8

1.3 Display .................................................................................................................... 9

1.4 Retrieving data – Information level ....................................................................... 11

1.5 Setting the system time ........................................................................................ 12

1.6 Adjust usage schedule settings ............................................................................ 13

1.7 Setting the party mode (heating circuit/auxiliary heating) ..................................... 15

1.8 Access advanced information level ...................................................................... 16

1.8.1 Setting holidays .............................................................................................. 17

1.8.2 Setting vacation times .................................................................................... 17

1.9 Operation level stucture ....................................................................................... 19

2 Commissioning ............................................................................................................ 20

2.1 Setting the system variant ID ................................................................................ 20

2.2 Activate and deactivate functions ......................................................................... 21

2.3 Edit settings .......................................................................................................... 23

2.4 Sensor calibration ................................................................................................. 24

2.5 Reset to factory default settings ........................................................................... 25

3 Manual operating mode .............................................................................................. 26

4 System variants ........................................................................................................... 27

4.1 Extending the basic system variant representations ............................................ 36

5 Solar circuit functions .................................................................................................. 39

5.1 Basic Control function ........................................................................................... 39

5.2 Storage ................................................................................................................. 41

5.3 Swimming pool ..................................................................................................... 42

5.4 Collector return flow sensor, Collector flow sensor .............................................. 43

5.5 Measurement of solar power and solar energy .................................................... 44

5.6 Rotation speed control .......................................................................................... 46

5.7 Collector overheating protection ........................................................................... 47

5.8 Collector minimum temperature ........................................................................... 48

5.9 Start up function ................................................................................................... 48

5.10 Forced pump operation (blocking protection) ..................................................... 48

5.11 Collector Antifreeze ............................................................................................ 49

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5.12 Two collector arrays (roof to the east and west) ................................................. 50

5.13 External heat exchanger ..................................................................................... 50

5.14 Auxiliary heating with secondary heat generator ................................................ 51

6 Heating circuit functions .............................................................................................. 52

6.1 Prescribing the room temperature set-points ....................................................... 52

6.2 Weather-compensated control ............................................................................. 52

6.2.1 Gradient characteristic .................................................................................. 52

6.2.2 4-point characteristic ...................................................................................... 54

6.3 3-point control ....................................................................................................... 56

6.4 Two-point control .................................................................................................. 56

6.5 Regulating by fixed value ..................................................................................... 57

6.6 Underfloor heating/screed drying ......................................................................... 58

6.7 Deactivation depending on the outdoor temperature ........................................... 59

6.7.1 OT deactivation temperature for daytime operating mode ............................. 59

6.7.2 OT deactivation temperature for night-time operating mode ......................... 59

6.7.3 OT activation temperature for daytime operating mode ................................. 60

6.7.4 Summer operating mode (OM) ...................................................................... 60

6.8 Delayed outside temperature compensation ........................................................ 61

6.9 Remote operation ................................................................................................. 61

6.10 Optimization ........................................................................................................ 61

6.11 Raise return flow of external heating system ..................................................... 62

6.11.1 Main principle ............................................................................................... 62

6.11.2 Implementation ............................................................................................ 62

7 Domestic water circuit functions .................................................................................. 64

7.1 Domestic water heating in storage tank ............................................................... 64

7.2 Thermal Disinfection of the storage tank .............................................................. 64

8 System wide functions - all system variants ................................................................ 65

8.1 Automatic summer/winter switching ..................................................................... 65

8.2 Antifreeze ............................................................................................................. 65

8.3 Locking manual operating mode .......................................................................... 66

8.4 Locking the rotary switch ...................................................................................... 66

8.5 Enter a valid individual access code ..................................................................... 66

8.6 Temperature difference controller ........................................................................ 67

9 Malfunction .................................................................................................................. 68

9.1 Error list ................................................................................................................ 68

9.2 Sensor failure ....................................................................................................... 68

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9.3 Temperature monitoring ....................................................................................... 69

9.4 Error status register .............................................................................................. 69

9.5 SMS delivery in case of a system failure .............................................................. 70

10 Communication ........................................................................................................ 71

10.1 Communication module KOM232PC ................................................................. 72

10.2 Communication module iCon485 ...................................................................... 72

10.3 Communication module KOM232M ................................................................... 74

10.4 Data Modem DataMod11 .................................................................................. 75

10.5 ModBus-MBus-Gateway .................................................................................... 76

10.6 Description of the adjustable communication settings ....................................... 76

10.7 Memory module ................................................................................................. 77

10.8 55Viewer for visualization and remote maintenance. ........................................ 78

10.9 Data Logging ..................................................................................................... 79

11 Mounting ................................................................................................................... 80

12 Electrical connection ................................................................................................. 82

12.1 Notes for wire installation ................................................................................... 82

12.2 Surge Protection Measures ................................................................................ 82

12.3 Connecting the controller .................................................................................... 82

12.3.1 Connecting the sensors ............................................................................... 83

12.3.2 Connecting the pumps ................................................................................. 83

12.3.3 Legend for connection diagram ................................................................... 83

12.3.4 Wiring diagram ............................................................................................. 84

12.3.5 Terminal assignment for Outputs ................................................................. 85

12.3.6 Terminal assignment for inputs .................................................................... 87

13 Appendix ................................................................................................................... 88

13.1 Function block lists ............................................................................................. 88

13.2 Parameter list ..................................................................................................... 92

13.3 Resistance values ............................................................................................ 102

13.4 Technical specifications .................................................................................... 103

13.5 Accessories ...................................................................................................... 104

13.6 Function block settings in configuration levels ................................................. 105

13.7 Abbreviations .................................................................................................... 106

13.8 Access codes ................................................................................................... 107

13.9 Notes ................................................................................................................ 108

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Installation and operating manual KT-Elektronik

1 Operation

The controller is factory-provided with standard temperature settings and timing

programs and therefore ready for use.

The current date and time have to be set at initial operation of the controller (Chapter

1.5).

1.1 Controls

The operational controls are located on the front side of the controller.

1.1.1 Rotary pushbutton

Rotary pushbutton

Turn :

Display, select settings and function blocks

Push :

confirm selection or setting

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1.1.2 Rotary switch

The rotary switch is used to select the operating mode on the left hand and the basic

settings of the controller on the right hand.

Rotary switch – operating mode

Control on, display informations about

operating behaviour of unit (standard position)

Turning off the control functions

(Controller remains in operation)

Manual operating mode:

manual switching of pumps and valves,

position presetting in percent

Rotary switch – Settings

Solar-Turn-on threshold

Solar-Turn-off threshold

Scheduled time ranges and operating modes for

heating circuit (1), aux. heating (2) and hot water

circulation (3)

Party mode

System time:

Setting time, date and year

Configuration and settings level

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1.2 Operating modes for heating circuit

The operation of the heating circuit can be affected depending on time and day of week.

Thereto different set-points for night and day exist. A usage schedule determines when

to operate in day-time OM or night-time OM. It is possible to deactivate schedules

(without deleting them) and to specify manually to operate permanently in day-time or

night-time operating mode.

Icons on the display indicate the current OM for each function of the controller:

Daytime operating mode (nominal operation)

Values are permanently adjusted to meet the set-points entered for nominal operating

mode regardless of scheduled time ranges or summer operating mode settings.

Night-time operating mode (reduced operation)

Values are permanently adjusted to meet the set-points entered for reduced operation

regardless of scheduled time ranges.

Normal operating mode off

Normal operating mode is deactivated regardless of the scheduled time ranges. Only

equipment anti-freeze is ensured (if activated).

Automatic operating mode

The controller automatically switches between both modes depending on the time.

Manual operating mode

Manual control of valves and pumps (Chapter 3).

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1.3 Display

During operation, the display shows the current time as well as information about the

status of the controller. The usage periods are represented by black squares below the

row of numbers. Symbols mark the operational status of the controller.

Holiday operating

mode (OM)

Vacation OM

Malfunction

Frost protection OM

1Heating circuit 2Solar circuit 3Auxiliary heating,

domestic water

circuit

Automatic operating

mode Automatic operating

mode

Night-time operation Night-time operation

Daytime Operation Manual operating mode Daytime Operation

Manual operating mode Stand-by OM Manual operating mode

Stand-by OM Collector pump CP1 Stand-by OM

Circulation pump UP1 Collector heat exchanger

pump, CTP Circulation pump ZP

Valve M1 OPEN Storage tank pump SP1 Aux. heating NH

Valve M1 CLOSED Collector switching

valve CUV

Collector pump CP2

Temperature

difference switch TdS

Storage switching

valve SUV

Storage pump SP2

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Installation and operating manual KT-Elektronik

The following applies to the icon of the collector pump(s):

Icon or Description

Icon off Pump off

Icon flashes briefly Condition to turn on the pump is met but the

pump is still off because of the minimum idle

time.

Icon is on but disappears for a

short time in intervals

Condition to turn off the pump is met but the

pump is still running because of the minimum

running time.

Icon on Pump is running

The controller status can be viewed at operating mode level (Chapter 1.4).

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1.4 Retrieving data – Information level

In the standard rotary switch position „Information level“ one can retrieve

informations about time, date, vacation-times and holidays as well as the temperature

set-points for the connected sensors and their current temperature.

Note: Information can also be retrieved in level "manual operating mode". To do so,

select "Info", then confirm and proceed as described.

Procedure:

Select value.

The screen now displays different items one after the other, depending on the

configuration of the controller.

__:__ Current time

Outdoor temperature AF

Room temperature RF

Temperature at supply pipe sensor VF, heat circuit

Flow temperature from the collector to the storage tank CVF

Return flow temperature from the collector to the storage tank CVF

Temperature at storage tank sensor SF1

Temperature at storage tank sensor SF2

Temperature at solar collector CF1

2 Temperature at solar collector CF2

Operating hours of solar circuit

Set-point/threshold and actual value comparison.

When the time is marked in the display, pressing the rotary pushbutton will

show the date.

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Installation and operating manual KT-Elektronik

1.5 Setting the system time

System time and date have to be set during first start-up and after each loss of power

with a duration of more than 24 hours. This is indicated by a blinking time display.

Procedure:

Turn rotary switch to the position

“system time” (right hand).

Display: shows current time setting

Change the time setting.

Confirm the time set.

Display: shows current year setting

Change the year setting.

Confirm the year set.

Display: show current date setting (day.month)

Change date setting.

Confirm the date set.

Display: shows current time setting

Move the rotary switch back to the "Information

level" position (left hand).

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1.6 Adjust usage schedule settings

There are three separate usage schedules for

•Heating circuit

•Auxiliary heating

•Domestic water circulation

The following applies to each time program:

For each day of the week, three time ranges can be programmed. If only one time range

is needed, the start and end time of the second range have to be set to the same value.

The third range will then not be shown any more. If only two time ranges are needed, the

start and end time of the third range have to be set to the same value.

The time ranges for the control circuits are adjusted by means of their identification

numbers shown in the display:

1Heating circuit 3Auxiliary heating 3Domestic water circulation

Setting FS* Value range

Time range/day 1–7 1–7, 1, 2, 3, 4, 5, 6, 7, for which 1–7 = daily,

1 = Monday 2 = Tuesday, ..., 7 = Sunday

Beginning of first time range 06:00 00:00 to 24:00 hours; 15 minute increments

End of first time range 22:00 00:00 to 24:00 hours; 15 minute increments

Beginning of second time range 22:15 00:00 to 24:00 hours; 15 minute increments

End of second time range 22:15 00:00 to 24:00 hours; 15 minute increments

Beginning of third time range – 00:00 to 24:00 hours; 15 minute increments

End of third time range – 00:00 to 24:00 hours; 15 minute increments

* Factory default settings valid for heating circuit

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Installation and operating manual KT-Elektronik

Procedure: Turn rotary switch to position “Usage schedules”

Select circuit for which the time ranges shall be

set.

(only available circuits of the selected system

variant are offered)

Confirm selected circuit.

Display: 1–7

Select time range/day:

1–7 = daily,

1 = Monday 2 = Tuesday, ..., 7 = Sunday

Switch time range/day to edit mode:

Display: START, flashes

Change start time (15-minute increments).

Confirm start time. Display: STOP

Change stop time (15-minute increments).

Confirm stop time.

Display: START

The second time range is adjusted the same

way as the first one.

Repeat the procedure for each day to be scheduled.

Move the rotary switch back to the "Information level" position (left hand).

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1Heating circuit

3 Auxiliary heating

3 Domestic water

circulation

Note: Do not use menu 1–7 to check the scheduled time ranges. Selecting this

menu item after having adjusted the schedule will copy Monday times to all other

days of the week.

KT-Elektronik SOL3-5

1.7 Setting the party mode (heating circuit/auxiliary heating)

The party mode overrides the nominal operation of the controller by starting a new or

prolonging a programmed daytime mode time range for the duration of the time set for

the party mode. The party mode timer starts working once the rotary switch is moved to

the "automatic mode" position (left hand). When the timer runs out the party mode

function is reset to 00:00.

The party mode is set one after the other for each circuit with the rotary switch:

Setting FS Value range

initiate or continue nominal operation 0 h 0 to 48 h

Procedure: Move rotary switch to the position “party mode” .

Select the circuit for which daytime mode shall be initiated or prolonged.

1Heating circuit 2Storage tank auxiliary heating

Confirm selected circuit.

Display: shows 00:00 or remaining party timer time.

Set desired non-recurring duration.

Move the rotary switch back to the "Information level" position (left

hand).

Note:

The lapse of time of the party timer is displayed in 15 minute increments.

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Installation and operating manual KT-Elektronik

1.8 Access advanced information level

After entering the access code 1999 the following informations are accessible through

the menu items as described in chapter 1.4:

•Measured values for not needed sensor inputs of current system layout

•Volume flow rate

•Performance

•Holidays (editable)

•Vacation times (editable)

•Valve positions

•Binary input switching status

•Info 2 - The following values are sequentially displayed:

Controller-ID

Memory usage, Data logging module (chapter 10.9)

Modbus client address

Operating hours of solar circuit

Volume flow rate of flow sensor in solar circuit

Current performance of solar circuit

Total gain (rate) of solar circuit

Daily gain of solar circuit

Access advanced operation level:

Switch to configuration and settings level.

Display shows 0 0 0 0

Enter access code 1999.

Confirm code. Display shows 0 0 0 0

Move the rotary switch back to the "Information level" position (left

hand).

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Note:

Re-entering the access code 1999 hides the advanced informations.

KT-Elektronik SOL3-5

1.8.1 Setting holidays

On public holidays the time ranges entered for Sunday apply. The number of

programmable holidays is limited to 20.

Setting FS Level / Range

Holidays – Advanced information level / 01.01 to 31.12

Procedure: In the advanced information level select the

menu item "holidays". Display:

Confirm selection "holidays".

Eventually select item – – – –.

Enter edit mode for holiday. flashes

Change holiday setting.

Confirm the holiday set.

To enter more holidays reselect – – – – and repeat the steps highlighted in grey.

Select End

Leave menu "holidays".

Note: Holidays can alternatively be entered in level PA5 (Chapter 2.2).

Remove holiday:

In menu "holidays" select the holiday to be deleted.

Confirm selection.

Select item – – – –.

Delete holiday.

Note: Holidays that are not assigned to a fixed date should be deleted by the

end of the year, so they are not automatically taken over into the next year.

1.8.2 Setting vacation times

During vacation times the system is set to permanent reduced operation. The number of

programmable vacation times is limited to 10.

Setting FS Level / Range

Vacation (Beginning, End) – Advanced information level / 01.01 to 31.12

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Installation and operating manual KT-Elektronik

Procedure: In the advanced information level select the

menu item "vacations". Display:

Confirm selection "vacations".

Display: START, – –.– –

Eventually select item – – – –.

Enter edit mode for vacation time. flashes

Change beginning of vacation.

Confirm setting.

Display: STOP, – –.– –

Change end of vacation.

Confirm setting. Black squares are shown below

the figures 1 to 4 at the head of the display for

the assignment of the vacation to each control

circuit.

Select control circuits for which the vacation

shall be applied.

current vacation for heating circuit Rk1

The vacation can be assigned to a single circuit

or to any combination of circuits (Rk1, domestic

water circuit).

To enter more vacation times reselect – – – – and repeat the steps highlighted in grey.

Select End

Leave menu "vacations".

Note: Vacation times can alternatively be entered in level PA5 (Chapter 2.2).

Remove vacation:

In menu "vacations" select the beginning of the vacation time to be deleted.

Confirm selection.

Select item – – – –.

Delete vacation.

Note: Saved vacation times should be deleted by the end of the year, so they are not

automatically taken over into the next year.

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1.9 Operation level stucture

PA1/CO1: Heating circuit Rk1

PA3/CO3: Solar circuit

PA4/CO4: Auxiliary heating/domestic water heating

PA5/CO5: System wide

PA6/CO6: Communication

Anl: system variant ID

Fig. 2: Level structure

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Installation and operating manual KT-Elektronik

2 Commissioning

The configuration procedures and parametrization described in this chapter can only be

performed by entering a valid controller access code.

The access code provided by the factory for first time use can be found in the appendix.

To avoid an unauthorized use, it is recommended to cut out or black out the code.

Additionally the standard code can be replaced by an individual one (Chapter 8.5).

2.1 Setting the system variant ID

Several hydraulic system variants are available. Each variant is represented by an

identification number. The variants are illustrated in chapter 4. The available controller

functions are described in chapters 5, 6 and 7.

Editing the variant ID resets previously entered function blocks to factory default settings.

At parameter level, function block parameters and settings will be preserved. The variant

ID can be set at configuration level.

Procedure: Switch to configuration and settings level.

Display shows 0 0 0 0

Enter a valid access code.

Confirm code.

Display: PA1

Select system variant.

Switch to edit mode.

Edit system variant ID.

Confirm ID.

Display: End

Leave configuration and settings level.

Display: 0 0 0 0

Move the rotary switch back to the "Information level" position .

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KT-Elektronik SOL3-5 Installation guide

KT-Elektronik SOL3-5 Installation guide

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